Vane arm torque transfer plate

ABSTRACT

A vane arm connection system for a gas turbine engine includes a vane stem having a head with flat contact surfaces; a vane arm having a claw, the claw having opposed arms having inwardly facing surfaces engaging the flat contact surfaces of the head; and a torque transfer member having a body defining an opening for engaging the flat contact surfaces of the head of the vane stem, and at least one arm extending from the body to contact the claw, whereby load from torque is transferred away from the inwardly facing surfaces.

BACKGROUND OF THE DISCLOSURE

The present disclosure relates to gas turbine engines and, moreparticularly, to vane arm connection systems for gas turbine engines.

Gas turbine engines, such as those that power modern commercial andmilitary aircraft, generally include a compressor section to pressurizean airflow, a combustor section to burn a hydrocarbon fuel in thepresence of the pressurized air, and a turbine section to extract energyfrom the resultant combustion gases.

Some gas turbine engines include variable stator vanes that can bepivoted about their individual axes to change an operational performancecharacteristic of the engine. Typically, the variable stator vanes arerobustly designed to handle the stress loads that are applied to changethe position of the vanes. A mechanical linkage is typically utilized torotate the variable stator vanes. Because forces on the variable statorvanes can be relatively significant, forces transmitted through themechanical linkage can also be relatively significant. Variable vanesare mounted about a pivot and are attached to an arm that is in turnactuated to adjust each of the vanes of a stage. A specific orientationbetween the arm and vane is required to assure that each vane in a stageis adjusted as desired to provide the desired engine operation. Newercompressor designs have resulted in higher compression ratios and loads.Further, recent designs have more vanes distributed through roughly thesame space, resulting in decreased size, especially decreased diameter,of the vane stems. The point of connection of vane arms to vane stems isalso subjected to even larger forces, especially torques, during surgeload operation.

Sheet metal design of vane arms are used in legacy engines and are lowcost but are limited in terms of grip strength to the vane stem. Currentand future compressors tend to be of higher pressure ratio, generatinghigher loads which are limiting to the sheet metal design of a vane arm.Connection of a vane arm to a vane stem is typically made with a clawhaving arms which contact flat surfaces of the vane stem. However, withsuch a structure, as loads increase, force is applied to arms of theclaw which can tend to pry open the claw.

SUMMARY OF THE DISCLOSURE

In one aspect of the present disclosure, a vane arm connection systemfor a gas turbine engine, comprises a vane stem having a head with flatcontact surfaces; a vane arm having a claw, the claw comprising opposedarms having inwardly facing surfaces engaging the flat contact surfacesof the head; and a torque transfer member having a body defining anopening for engaging the flat contact surfaces of the head of the vanestem, and at least one arm extending from the body to contact the claw,whereby load from torque is transferred away from the inwardly facingsurfaces.

In another non-limiting configuration, the torque transfer membercomprises a plate having the body and the opening, and two armsextending from an edge of the body and defining claw contact surfaces.

In still another non-limiting configuration, the body has two spacedsurfaces at least partially defining the opening, and the at least twospaced surfaces engage flat contact surfaces of the head of the vanestem.

In a further non-limiting configuration, the body further comprises anend surface closing the opening at an end opposite to the two arms,whereby the end surface holds the body in place against movement off ofthe flat contact surfaces of the head of the vane stem.

In a still further non-limiting configuration, the at least one armengages the claw at a location other than the inwardly facing surfacesof the claw.

In yet another non-limiting configuration, the opposed arms of the clawhave proximal and distal surfaces, and the at least one arm extends fromthe torque transfer member to contact at least one of the proximal anddistal surfaces.

In another non-limiting configuration, the claw has an upper bodydefining an opening for securing to the vane stem and two claw armsextending downwardly from the upper body and engaging the flat contactsurfaces of the head, the torque transfer member is positioned below theupper body of the claw, and within the claw arms, and the at least onearm extends outside of the claw arms to contact the at least one of theproximal and distal surfaces.

In still another non-limiting configuration, the two arms extend awayfrom each other to contact at least one of the proximal and distalsurfaces of both of the claw arms.

In a further non-limiting configuration, contact between the at leastone arm and the claw is along a line that is perpendicular to contactbetween the opening and the flat contact surfaces of the head.

In a still further non-limiting configuration, the torque transfermember has a distal end when mounted to the vane stem, and furthercomprises a cutout for receiving an anti-rotation tab to preventrotation during assembly.

In yet another non-limiting configuration, the torque transfer membercomprises two arms extending laterally in opposite directions from oneedge of the body, and the cutout is between the two arms.

In another non-limiting configuration, the body has a width sized to fitbetween the opposed arms of the claw, and the at least one arm extendslaterally beyond the width of the body.

In still another non-limiting configuration, the at least one armcomprises two arms extending laterally in opposite directions beyond thewidth of the body.

In a further non-limiting configuration, the body and the at least onearm of the torque transfer member comprise a single piece part ofstamped sheet metal.

In a still further non-limiting configuration, a torque transfer memberfor a vane arm connection comprises a body having an opening with spacedflat sides for engaging flat contact surfaces of a head of a vane stem,and at least one arm extending laterally from an edge of the body toengage a surface of a claw of a vane arm engaged with the vane stem.

In yet another non-limiting configuration, the body and the at least onearm comprise a single piece part of stamped sheet metal.

In another non-limiting configuration, the body has a width sized to fitbetween opposed arms of the claw, and the at least one arm extendslaterally beyond the width of the body.

In a further non-limiting configuration, a method for retrofitting avane arm having a claw to a vane stem having a head with flat contactsurfaces, wherein the claw comprises claw arms for engaging the flatcontact surfaces of the head, comprises the step of positioning a torquetransfer member on the vane stem, the torque transfer member having anopening engaging the flat contact surfaces of the head, and at least onearm extending to engage the claw, wherein the positioning step positionsthe at least one arm to engage the claw when the vane stem is subjectedto a torque relative to the vane arm.

In a still further non-limiting configuration, the method comprisespositioning the torque transfer member within the claw arms, andmounting the torque transfer member and the claw together to the vanestem whereby the opening of the torque transfer member and the claw armsengage the flat contact surfaces of the head, and the at least one armengages a surface of the claw.

In yet another non-limiting configuration, the claw arms engage the flatcontact surfaces of the head at opposed surfaces, and the surfaceengaged by the at least one arm is not the opposed surfaces.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of non-limiting embodiments of the disclosurefollows, with reference to the attached drawings, wherein:

FIG. 1 is a schematic cross-section of a non-limiting example of a gasturbine engine architecture;

FIG. 2 is a schematic view of a variable vane system for a gas turbineengine;

FIG. 3 is a partial perspective view of one stage of a variable vanesystem for a gas turbine engine;

FIG. 4 is a partial perspective view of a variable vane system for a gasturbine engine according to one disclosed non-limiting embodiment;

FIGS. 5A-5C illustrate a known vane arm connection to a vane stem;

FIG. 6 shows a non-limiting embodiment of a torque transfer plateaccording to the disclosure;

FIG. 7 is a top view showing mounting of the torque transfer plate ofFIG. 6 between a vane arm and a vane stem; and

FIG. 8 shows an end view, partially in section, of the torque transferplate of FIG. 6 mounted between a vane arm and a vane stem.

DETAILED DESCRIPTION

FIG. 1 schematically illustrates a gas turbine engine 20. The gasturbine engine 20 is disclosed herein as a two-spool geared turbofan(GTF) that generally incorporates a fan section 22, a compressor section24, a combustor section 26 and a turbine section 28. Alternative enginearchitectures might include various other sections, systems or featureswhich are not illustrated herein. The fan section 22 drives air along abypass flowpath while the compressor section 24 drives air along a coreflowpath for compression and communication into the combustor section26, and then expansion through the turbine section 28. Although depictedas a GTF in the disclosed non-limiting embodiment, it should beunderstood that the concepts described herein are not limited to usewith a GTF as the teachings may be applied to other types of turbineengines such as a direct drive turbofan with high or low bypassturbofan, turbojets, turboshafts, and three spool (plus fan) turbofanswherein an intermediate spool includes an intermediate pressurecompressor (IPC) between a low pressure compressor (LPC) and a highpressure compressor (HPC), and an intermediate pressure turbine (IPT)between the high pressure turbine (HPT) and the low pressure turbine(LPT).

The engine 20 generally includes a low spool 30 and a high spool 32mounted for rotation about an engine central longitudinal axis Arelative to an engine static structure 36 via several bearingcompartments 38. The low spool 30 generally includes an inner shaft 40that interconnects a fan 42, a low pressure compressor 44 (LPC) and alow pressure turbine 46 (LPT). The inner shaft 40 drives the fan 42directly or thru a geared architecture 48 to drive the fan 42 at a lowerspeed than the low spool 30. An exemplary reduction transmission is anepicyclic transmission, namely a planetary or star gear system.

The high spool 32 includes an outer shaft 50 that interconnects a highpressure compressor 52 (HPC) and high pressure turbine 54 (HPT). Acombustor 56 is arranged between the HPC 52 and the HPT 54. The innershaft 40 and the outer shaft 50 are concentric and rotate about theengine central longitudinal axis A which is collinear with theirlongitudinal axes.

Core airflow is compressed by the LPC 44 then the HPC 52, mixed withfuel and burned in the combustor 56, then expanded over the HPT 54 andthe LPT 46. The turbines 54, 46 rotationally drive the respective lowspool 30 and high spool 32 in response to the expansion. The main engineshafts 40, 50 are supported at a plurality of points by the bearingcompartments 38. It should be understood that various bearingcompartments 38 at various locations may alternatively or additionallybe provided.

In one example, the gas turbine engine 20 is a high-bypass gearedaircraft engine with a bypass ratio greater than about six (6:1). Thegeared architecture 48 can include an epicyclic gear train, such as aplanetary gear system or other gear system. The example epicyclic geartrain has a gear reduction ratio of greater than about 2.3:1, and inanother example is greater than about 3.0:1. The geared turbofan enablesoperation of the low spool 30 at higher speeds which can increase theoperational efficiency of the LPC 44 and LPT 46 to render increasedpressure in relatively few stages.

A pressure ratio associated with the LPT 46 is pressure measured priorto the inlet of the LPT 46 as related to the pressure at the outlet ofthe LPT 46 prior to an exhaust nozzle of the gas turbine engine 20. Inone non-limiting embodiment, the bypass ratio of the gas turbine engine20 is greater than about ten (10:1), the fan diameter is significantlylarger than that of the LPC 44, and the LPT 46 has a pressure ratio thatis greater than about five (5:1). It should be understood, however, thatthe above parameters are only exemplary of one embodiment of a gearedarchitecture engine and that the present disclosure is applicable toother gas turbine engines including direct drive turbofans, where therotational speed of the fan 42 is the same (1:1) of the LPC 44.

In one example, a significant amount of thrust is provided by the bypassflow path due to the high bypass ratio. The fan section 22 of the gasturbine engine 20 is designed for a particular flightcondition—typically cruise at about 0.8 Mach and about 35,000 feet(10668 meters). This flight condition, with the gas turbine engine 20 atits best fuel consumption, is also known as bucket cruise thrustspecific fuel consumption (TSFC). TSFC is an industry standard parameterof fuel consumption per unit of thrust.

Fan pressure ratio is the pressure ratio across a blade of the fansection 22 without the use of a fan exit guide vane system. Therelatively low fan pressure ratio according to one example of a gasturbine engine 20 is less than 1.45. Low corrected fan tip speed is theactual fan tip speed divided by an industry standard temperaturecorrection of (“T”/518.7)0.5 in which “T” represents the ambienttemperature in degrees Rankine. The low corrected fan tip speedaccording to one example of a gas turbine engine 20 is less than about1150 fps (351 m/s).

With reference to FIG. 2 , one or more stages of the LPC 44 and/or theHPC 52 include a variable vane system 100 that can be rotated to changean operational performance characteristic of the gas turbine engine 20for different operating conditions. The variable vane system 100 mayinclude one or more variable vane stages.

The variable vane system 100 may include a plurality of variable statorvanes 102 (see also FIG. 3 ) circumferentially arranged around theengine central axis A. The variable stator vanes 102 each include avariable vane body that has an airfoil portion such that one side of theairfoil portion generally operates as a suction side and the opposingside of the airfoil portion generally operates as a pressure side. Eachof the variable stator vanes 102 generally spans between an innerdiameter and an outer diameter relative to the engine central axis A.

Each of the variable stator vanes 102 includes an inner trunnion 104that is receivable into a corresponding socket and an outer trunnion 106mounted through an outer engine case 108 such that each of the variablestator vanes 102 can pivot about a vane axis T (shown in FIG. 4 ).

The variable vane system 100 further includes a synchronizing ringassembly 110 to which, in one disclosed non-limiting embodiment, each ofthe outer trunnions 106 are attached through a vane arm 112 connected toring assembly 110 for example with a fastener extending along arespective axis D. It should be appreciated that although a particularvane arm 112 is disclosed in this embodiment, various linkages ofvarious geometries may be utilized.

The variable vane system 100 is driven by an actuator system 118 with anactuator 120, a drive 122 and an actuator arm 124 (also shown in FIG. 4). Although particular components are separately described, it should beappreciated that alternative or additional components may be provided.

With reference to FIG. 4 , the vane arm 112 links each outer trunnion106 to the synchronizing ring assembly 110. Rotation of thesynchronizing ring assembly 110 about the engine axis A (FIG. 1 ) drivesthe vane arm 112 to rotate the outer trunnion 106 of each of thevariable stator vanes 102.

Each vane arm 112 interfaces with the synchronizing ring assembly 110via a pin 130. The pin 130 is swaged to an end section 140 of the vanearm 112 within an aperture 142. Of course, other connections betweenvane arm 112 and ring 110 could be utilized.

FIG. 4 shows that vane arms 112 engage with vane stems 160. This pointof engaging is subject to potentially significant torque duringoperation of the engine and also the system to position the vanes asdesired. Under surge loads, this torque is increased even further.

FIGS. 5A-C illustrate engagement of a known vane arm and claw structurewith a vane stem. As shown, vane stem 160 can have a base 162 whichextends to other systems of the engine, for example to vanes which areto be positioned around axis T as discussed above. Extending from base162 is a head 164 which defines two oppositely facing flat contactsurfaces 166. A typical vane stem 160 then also has a round portion 168extending upwardly from the head 164, and the vane arm can be secured tothe vane stem with a nut 170 which can, for example, be threaded to theround portion 168. Alternatively, this connection can be by way of athreaded opening in the vane stem, and a bolt threaded into the opening.This type of connection is illustrated in FIGS. 7 and 8 discussed below.

Also as illustrated, a vane arm typically has a claw structure 172 (seealso FIG. 4 ) to securely engage the vane stem. Claw structure 172 has acentral portion 174 which has an opening 176 for receiving round portion168 of vane stem 160. Claw arms 178 extend from central portion 174 andtypically curve downwardly to define spaced, inwardly directed surfaces180 which engage with flat contact surfaces 166 of head 164. In thisway, claw structure 172 is engaged with vane stem 160. As set forthabove, however, current and planned designs of gas turbine enginesinvolve use of more vanes and therefor more vane stems, which results inthe need for smaller diameter vane stems. This, in turn, results insmaller flat contact surfaces 166 to be engaged by inwardly directedsurfaces 180, and therefore an increased chance that inwardly directedsurfaces 180 will deflect or spread relative to flat surfaces 166,particularly under surge load conditions wherein the torque (see arrowX, FIG. 5C) is significantly increased.

Referring to FIG. 6 , a torque transfer member or plate 182 isillustrated. Torque transfer plate 182 in this configuration is asubstantially flat member having a body portion 184 defining an opening186, and having at least one arm 188, in this configuration two arms188, that serve to contact a claw of a vane arm and transfer some of theforce due to torque that would otherwise tend to pry open the claw arms.Force is transferred to a different part of the claw where there issignificantly more stiffness, such that connection of vane arm 112 tovane stem 160 is more able to withstand surge loads without prying openthe claw. Thus, torque capacity before yield is increased.

FIGS. 7 and 8 illustrate a torque transfer plate 182 in position in avane arm connection system, mounted to a vane stem 160 within a claw 172of a vane arm 112. As shown, opening 186 engages flat contact surfaces166 of head 164 such that torque transfer plate 182 is non-rotatablymounted to the vane stem 160. In addition, arms 188 extend outside ofclaw 172 and engage with a surface of claw 172 that is not the opposingsurfaces 180, such that the engagement of torque transfer plate 182 withclaw 172 does not create forces that tend to pry the claw arms open.Rather, force is transferred from where it would normally occur,illustrated by arrow A in FIG. 7 , to engage on an edge surface 190 ofclaw 172 where the claw can accept the force in a direction indicated byarrow B in FIG. 7 , without being pried open. In the configurationillustrated, the force is transferred 90 degrees around claw 172.

Referring back to FIG. 6 , further details of this configuration oftorque transfer plate 182 are discussed. In this non-limitingconfiguration, body 184 has a width W sized to fit between claw arms 178of claw 172 (illustrated in FIG. 8 discussed below). Within the body184, opening 186 is defined having two spaced surfaces 192 which can bespaced to engage with flat contact surfaces 166 of head 164. This can bea press fit, or a fit designed to be snug with little or no lateralplay.

Opening 186 also has a length L which is configured to accept the flatcontact surfaces 166 of head 164 as best shown in FIG. 7 . This lengthdimension can be snug or can have some play. In addition, it should benoted that other configurations of this portion of the opening arepossible, for example where only one end surface 194 of the opening thatis opposite to arms 188 is utilized, and the other end of the openingcan be open. End surface 194 serves to hold torque transfer plate 182 inplace when mounted within a claw 172 on head 164. End surface 194prevents plate 182 from sliding out in the direction toward arms 188,while arms 188 engage against claw 172 and prevent plate 182 fromsliding out in the other direction. Thus, the portion of body 184indicated at 196 could alternatively be open, for example to savematerial and weight.

FIG. 6 illustrates plate 182 formed from stamped sheet metal such thatbody 184 and arms 188 are a single integral piece part. While this isbeneficial from a simplicity and ease of manufacturing standpoint, otherconfigurations are possible. For example, plate 182 could be made fromcomposite or sintered metal, and could be additively manufactured, ormachined instead of stamped from sheet metal, or could generally befabricated by any known method. However, sheet metal stamping is oneparticularly cost-effective method for high volume production.

FIG. 7 shows a top view of plate 182 mounted within claw 172 on head 164of vane stem 160. As shown, body 184 is sized to fit within arms 178 ofclaw 172. Arms 188 extend outside of claw 172 to a dimension wider thanthe space between arms 178 and, in this non-limiting configuration,engage against a distal edge surface 198 of claw 172. As set forthabove, this serves to transfer force of engagement between flat contactsurfaces 166 of head 164 and claw 172 from a prying force applied toinner surfaces 180 of arms 178, through plate 182 to distal edge surface198 where the force is not structurally detrimental to the claw. Asshown, engagement of contact surfaces 166 of head 164 with both claw 172and plate 182 is along flat surfaces in one plane X, but engagementbetween plate 182 and claw 172 is along flat surfaces in another plane Ythat is turned approximately 90 degrees, or is substantiallyperpendicular, to plane X. Thus, force due to a torque load asillustrated by arrow Z can be at least partially transferred from planeX to plane Y, where it will not tend to pry open claw arms 178.

It should be appreciated that although plate 182 is shown in FIG. 7 witharms 188 engaging distal edge surface 198 of claw 172, in someconfigurations (not illustrated), plate 182 could be assembled in thereverse position such that arms 188 engage against a proximal edgesurface 200 of claw 172, with substantially the same result. In eitherposition, arms 188 have claw contact surfaces 189 that contact eitherdistal edge surface 198 or proximal edge surface 200 of claw 172. Also,while FIGS. 6-8 illustrate one non-limiting configuration wherein arms188 engage distal or proximal edge surfaces of the claw, otherconfigurations are possible, with arms 188 engaging against otherportions of claw 172, so long as the contact is not with opposedsurfaces 180 or otherwise within arms 178 and outwardly directed so asto pry arms 178 apart.

Arms 188 extend at least as wide as arms 178 so that the transferredforce can be transferred to as much area as possible, thereby alsopotentially reducing localized stress caused by such force, in additionto transferring such force away from plane X.

In FIG. 5B, a configuration of vane stem is shown wherein a threadedportion 168 is mounted to the vane stem, and a nut 170 is threaded ontothis threaded portion to complete assembly. FIGS. 7 and 8 illustrate analternative configuration wherein a bolt 202 is threaded into a threadedopening (not illustrated) of the vane stem. Either of theseconfigurations serves to secure claw 172 and plate 182 in place on head164.

Referring back to FIGS. 6 and 7 , plate 182 can have a cutout 204positioned between arms 188. Cutout 204 accepts an anti rotation tab ofthe claw and helps to hold all components in place during assembly.Cutout 204 also serves to conserve material and reduce weight.

It should be appreciated that both new and existing systems can benefitfrom plate 182 as disclosed herein. Retrofitting plate 182 to systemshaving only claw 172 mounted to head 164 is possible. Plate 182 can beimplemented in such systems by positioning plate 182 within claw 172,with body 184 below the upper body of the claw and between the claw armsand arms 188 extending laterally outside of claw 172. Then opening 186and arms 178 can be positioned on head 164 to engage flat contactsurfaces 166 of head 164. Then these components can be secured in placewith bolt 202 or nut 170 depending upon the configuration in use.

Surfaces of claw 172 have been referred to herein as distal andproximal, and these terms should be considered when viewed from thenon-claw end of the vane arm. Thus, from the non-claw end of the vanearm, distal edge surface 198 would be the furthest away edge of claw172, while proximal edge surface 200 would be the closer edge surface ofclaw 172.

The foregoing description should be considered as an exempla of astructure of the disclosed torque transfer plate, and the featuresdisclosed herein should be seen as illustrative but not limiting uponthe disclosure. Various non-limiting embodiments are disclosed. However,one of ordinary skill in the art would recognize that variousmodifications and variations in light of the above teachings will fallwithin the scope of the appended claims. It is therefore to beunderstood that within the scope of the appended claims, the disclosuremay be practiced other than as specifically described.

1. (canceled)
 2. The torque transfer member of claim 15, wherein the atleast one arm comprises two arms extending away from each other from theedge of the body.
 3. (canceled)
 4. The torque transfer member of claim15, wherein the body further comprises an end surface closing theopening at an end opposite to the two arms, whereby the end surfaceholds the body in place against movement off of the flat contactsurfaces of the head of the vane stem.
 5. (canceled)
 6. (canceled) 7.(canceled)
 8. (canceled)
 9. The torque transfer member of claim 15,wherein the at least one arm defines a claw contact surface that isperpendicular to the spaced flat sides of the opening.
 10. The torquetransfer member of claim 15, further comprising a cutout for receivingan anti-rotation tab to prevent rotation during assembly.
 11. The torquetransfer member of claim 10, wherein the at least one arm comprises twoarms extending laterally in opposite directions from one edge of thebody, and wherein the cutout is between the two arms.
 12. (canceled) 13.The torque transfer member of claim 17, wherein the at least one armcomprises two arms extending laterally in opposite directions beyond thewidth of the body.
 14. (canceled)
 15. A torque transfer member for avane arm connection, comprising a body having an opening with spacedflat sides facing each other for engaging flat contact surfaces of ahead of a vane stem, and at least one arm extending laterally from anedge of the body to engage a surface of a claw of a vane arm engagedwith the vane stem.
 16. The torque transfer member of claim 15, whereinthe body and the at least one arm comprise a single piece part ofstamped sheet metal.
 17. The torque transfer member of claim 15, whereinthe body has a width sized to fit between opposed arms of the claw, andwherein the at least one arm extends laterally beyond the width of thebody.
 18. (canceled)
 19. (canceled)
 20. (canceled)
 21. The torquetransfer member of claim 15, wherein the spaced flat sides of theopening are parallel to each other.
 22. The torque transfer member ofclaim 17, wherein the width of the body is defined by two paralleloutwardly facing edge that are also parallel to the spaced flat sides ofthe opening.
 23. The torque transfer member of claim 15, wherein theopening has a long dimension and a short dimension, and wherein theparallel spaced flat sides are arranged along the long dimension.